Portable basket colony for growing and transport and method of use

ABSTRACT

A colony basket and method of using the same for handling poultry from DOC through the growing process and on to a production facility comprising a harvesting system, a loading system, a transport system, an unloading and storing system, hanging system and cleaning system. The system and method performs the steps of harvesting and colonizing live poultry into a singly stackable and transportable colony basket, stacking and loading the trays on a transport, unloading and temporarily storing the poultry for subsequent processing. The system and method further includes the use of a modular colony basket for interchangeable use with the described system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of Ser. No. 14/243,443filed Apr. 2, 2014; said application Ser. No. 14/243,443 is acontinuation-in-part of U.S. patent application Ser. No. 13/777,767filed Feb. 26, 2013 and issued as U.S. Pat. No. 9,119,382 entitledPortable Basket Colony for Growing and Transport and Method of Use; theentire disclosures of which are incorporated herein by reference.

BACKGROUND OF INVENTION

1. Field

The field relates generally to poultry processing and more particularlyto handling, growing and transporting live poultry.

2. Background Art

Loading and unloading birds and transportation of live birds from thehatchery stage through the kill stage at a production facility is achallenging task. The birds have to be gathered, contained andtransferred to a transport means and subsequently unloaded with minimaldamage or harm to the animal, which is challenging because birdsinstinctively resist such movement. For example, transport of livepoultry from the hatchery to growing houses, and from growing houses toprocessing facilities is required. One method of transport of livepoultry is containing the birds in cages and stacking the cages on atruck with a flatbed trailer for transport. Loading and unloadingtrailers with live animals, particularly from a location where theanimals are grown or raised to a processing facility, can in the case ofchickens, increase the stress level of the animal. With heightenedstress, animals are more likely to have increased body temperature,experience bruising, dislocated wing/leg joints and potential tissuedamage along with an increased pH level, which may affect the quality ofthe muscle. Once the birds are captured in cages, the cages must beloaded on the trailer.

Existing systems involve crews of catchers to unload the birds from thegrowing colonies and load them for transport means. Loading of the cageson the trailer consumes the full time of one operator to move cages fromthe house or growing area to the trailer and it requires skill to stackcages on the trailer so that they can be properly secured for transport.The cages often become damaged in this operation over time and need tobe repaired and eventually replaced. Damage to the cages often involvesthe doors through which the birds are inserted. Poorly operating doorsleads to increased time to load cages and potential bird damage.

There are significant labor issues because it is very labor intensiveand requires some level of skill and training. There are health issuesfor both the birds and the handlers. The labor intensive handling of thebirds promotes infections of the handler and risks harm to the birds.This results in numerous health and safety concerns. The cages are pronefor damage which can cause bird damage and extensive time and labor isutilized to fill the cages with birds and load and secure them fortransport. The cages or other transport containers also have to becleaned prior reuse, which can also be a labor intensive and costlyeffort.

Loading of poultry is a cumbersome and time consuming task. In thecatching process, the poultry are placed into cages. Some cage designsconsist of “drawers” and can vary from 10 to 15 drawers averaging a20-25 bird capacity per drawer. Birds can be placed into the cageseither manually or by semi-automatic means. A forklift then can load aflatbed truck with 18-22 cages that are stacked in pairs. Once the cagesare in place, each stack has to be secured by chains to the frame of thetrailer.

Semi-automated methods of harvesting the birds in the houses haveencountered mechanical and functional problems. In one sense thissemi-automated method eliminates the need for operators to physicallypick up the birds. However, operators are still needed to operate theequipment and to move the birds forward and away from the sides of thehouse. Therefore, some handling is still necessary.

Plastic poultry trays or drawers are sometimes used to transport andhouse birds temporarily, however, these systems are temporal and onlyused during certain stages and are not integral with growing systems ortransport systems. Use of such trays or drawers still requiresignificant handling of birds, though they may be somewhat more durablethan metal cages. Further, these plastic poultry trays, though lessoften than the standard cages, are also subject to damage or breakageresulting in a need to replace the entire tray, even though only onearea of the tray may be cracked or otherwise damaged. The plastic traysare likely easier to clean and sanitize than the standard cage but giventhe size of the typical plastic tray and the webbing of the mesh, theyalso can be difficult to clean. Also, storing trays when they are not inuse can consume a large amount of space.

As noted above, problems occur with, loading, unloading, harvesting,placing birds into cages (plastic drawers or trays), loading the cageson a transport, and transporting to the processing facilities. Also,current processes are labor intensive and costly. The problems occur asthe DOC (Day Old Chicks) are transitioned from the hatcheries to thegrowing centers and then to the production facilities. A new system andmethod for harvesting, loading, growing, transporting, and unloading isneeded that addresses the above problems by reducing physical handlingof the birds from the hatchery stage through the kill and productionstage. In the new system and method, the device by which the birdsshould be transported should be reusable, interchangeable, and easilycleaned.

BRIEF SUMMARY OF INVENTION

The technology involves a system and method for handling poultrycomprising a colony basket apparatus utilized throughout the process oftransitioning the DOC from the hatchery, to the growing facility,through the growing process, and on to the production facility. Thecolony basket apparatus is utilized for harvesting, loading andunloading, growing, transport, storing and holding through the shacklingprocess prior to the kill process. The method utilizes the colony basketapparatus to perform the steps of retrieving and loading a grouping ofthe DOC into the colony basket at the hatchery, transporting the samegrouping of birds in the same colony basket to the growing facility,loading the colony basket containing the original grouping of birds intothe colony system of the growing facility, growing the DOC to Broilers(chickens bred and raised specifically for meat production) in theoriginal colony basket in which they were installed, removing andharvesting live poultry from the colony system while maintaining thesame grouping of birds in the same colony basket in which they wereoriginally placed, stacking and loading the colony basket of Broilers ona transport, transporting to a poultry production facility, unloadingthe colony basket and temporarily storing the poultry in the same colonybasket for subsequent killing. The invention more particularly relatesto a new portable colony basket for holding and making possible allnecessary functions for the poultry animals from the DOC stage, throughgrowing, through transport and up to production while maintaining agrouping of birds or subset thereof in the same colony basket throughoutthe process all of the way through the shackling process.

The concept of harvesting poultry utilizing one type of colony basketuniformly throughout the entire process from capturing the DOC at thehatchery to growing houses equipped with colony systems and on toproduction will make the process more efficient and will result in lessworker and animal stress by resolving many of the problems related tothe current methods of manually catching birds and placing in cages orother containers or using semi-automated systems to harvest andtransition poultry. With the present invention, stackable tray colonybaskets can be utilized that can be placed into and retrieved fromcolony systems in growing houses using automated systems and can betransferred and retrieved from transports when transitioning betweenlocations within the overall process and the colony baskets can befurther integrated with feeding and watering systems. The trays can bemade from molded plastic or other material including metal aluminummetal and can have an open grid flexible flooring elevated above a lowermanure trap flooring to keep the birds out of their manure and the sidescan be vented. The bottoms can have an open grid pattern bottom to allowthe birds to grasp with their paws to stabilize and reduce wingflapping, but the floor can also be flexible to reduce injury to thebird. The grid pattern also allows debris and feces to fall out toreduce cleaning and increased airflow to ventilate the birds. The topand bottom perimeter edges of the cages can be complimentary in shapefor ease of stacking and stability reducing lateral movement of thestacked trays with respect to each other. The sides of the trays canalso have vented openings. Once an upper tray is stacked on top of alower tray, birds placed in the lower tray are contained. The upper mosttray in a stack of trays can be capped by an additional empty tray orother cover or ceiling in the colony system or in the transport or otherautomated transitioning means.

An empty stack of colony baskets can be transported to a hatchery andloaded with DOC. The stack of colony baskets containing DOC can beloaded on a transport rack, which receives the colony baskets andtransported to a growing house from the hatchery. The colony baskets canbe unloaded from the transport rack to be transferred into a poultryhouse colony system manually or the transfer can by automated by apowered mover or conveyor and/or loading system. This method providesthat no container stacks have to be manually or mechanically un-stackedfor loading poultry because the DOC are already in the colony baskets.Previous systems required that trays be removed from a stack and thenthe poultry would be loaded into the trays and the trays are re-stacked,a powered mover can transport the trays to the outside to be loaded ontothe trailer. The process of loading and unloading birds in the growinghouse has been eliminated.

The construction of the trailer can be a flatbed trailer with verticalframework to make up the structural integrity as well as to hold thestacks of individual colony baskets. There can be a plurality ofvertical and horizontal rails to insure the structure and flexibility ofthe size and number of colony baskets the transport is capable ofhandling.

With the design of the present invention, there can be a frame workconstructed on the transport trailer holding a lightweight material thatcan be pulled alongside the trailer to cover the sides. This shroud cancreate an envelope in which the environment can be better controlled andprovide a more suitable environment for the animals.

Once the trailer arrives at the plant, the colony baskets can beunloaded and automatically moved into a warehouse or holding facility.This process can be performed as trucks arrive in order to build anentire storage of birds for a production shift. The trucks can beautomatically unloaded in a very short period of time, thus eliminatingthe need for a forklift. The system can work in a “last-in first-out”method. The process can be improved through the efficiency of bringingthe birds in the same colony basket that originated at the hatchery andthe same colony basket continuing through the growing process and on tothe production plant kill area and not consuming time loading andunloading birds into and out of cages or other containers.

The automated unloading can be done automatically to pull the trays offthe trailer (or flatbed of transport) from the side of the truck in thestacked formation into a transport rack or onto either a conveyor orpull chain system. The transport rack or the conveyor can take the traysto the staging area where they can be un-stacked manually or by usingdestacker equipment.

With the proposed method, the colony baskets provide a perfecttransport, growing container and housing means all in one unit to movethe birds through the entire process. This system can eliminate theunnecessary handling of the birds and possibly make the process moreefficient.

In another implementation of the present technology, a modular colonybasket (modular tray) is used for the colony basket apparatus. Themodular basket can comprise a floor formed of mesh panels and modularside walls that receive a beam extending through a hinge elementconnecting mesh panels to the floor. As in the previously describedcolony basket, the modular basket is stackable with other modularbaskets and can have all of the functionality and interfaces as thenon-modular implementation. The modularity of the basket allows thebasket or tray to be periodically disassembled for routine scheduledcleaning and sanitizing, which would be easier than trying to clean andsanitize the whole basket. Further, if only a small section of abasket/tray is damaged, the modularity provided with this implementationallows a given section to be replaced without disposing of the entiretray.

There are a number of advantages to the design of the present inventionfor harvesting poultry. Safety is increased for the handler and thebirds and health risks are reduced. The efficiencies of handling andtransporting birds is improved and the process is less labor intensiveand causes less stress on animals.

Moreover, because the present invention teaches the use of a modularcolony basket, a method is provided wherein the devices used totransport the birds may be easily disassembled and cleaned before beingreassembled.

These and other advantageous features of the present invention will bein part apparent and in part pointed out herein below.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, reference may bemade to the accompanying drawings in which:

FIG. 1 is a colony basket integrated with a watering and feeding system;

FIG. 2A is a perspective view illustration of stacked colony baskets;

FIG. 2B is a side view illustration of stacked colony baskets;

FIG. 2C is an end view illustration of stacked colony baskets;

FIG. 3A is an illustration of a colony basket rack;

FIG. 3B is an illustration of a sectional detail of a colony basketrack;

FIG. 4A is a colony basket rack;

FIG. 4B is a side plan view of a colony basket;

FIG. 4C is a side plan view of a colony basket;

FIG. 4D is a colony basket rack support;

FIG. 4E is a colony basket rack conveyor assembly;

FIG. 5A is a colony basket rack support;

FIG. 5B is a colony basket rack conveyor assembly;

FIG. 6 is a flow diagram of the colony basket methodology;

FIG. 7 is an illustration of the hatchery conveyor, DOC counter and eggshell separator;

FIG. 8 is an illustration of a colony system;

FIG. 9 is an illustration of loading colony baskets from a rack to acolony system;

FIG. 10 is an illustration of the colony system operation;

FIG. 11 is an illustration of a transport loading system;

FIGS. 12A, 12B and 12C are an illustration of loading a transport;

FIGS. 13, 14, 15, 16, 17, 18 and 19 are an illustration of transferringcolony basket stacks from a colony system to a trailer;

FIGS. 20, 21 and 22 are an illustration of retrieving colony basketstacks from a trailer;

FIGS. 23 and 24 are an illustration of transferring colony baskets to akill line;

FIGS. 25 and 26 are an illustration of colony baskets traveling throughthe kill line and the cleaning station.

FIG. 27 is a perspective view of an assembled modular poultry raisingbasket according to the teachings of the present invention;

FIG. 28 is a top view of the poultry raising basket of FIG. 27;

FIG. 29 is a side view of the poultry raising basket of FIG. 27;

FIG. 30A is a perspective view of a floor panel for the basket of FIG.27;

FIG. 30B is an alternative perspective view of the floor panel of FIG.30A;

FIG. 30C is a bottom perspective view of the floor panel of FIGS. 30Aand 30B.

FIG. 30D is a front view of the floor panel of FIGS. 30A, 30B, and 30C.

FIG. 31 is a detailed view of a corner of the floor panel of FIGS. 30Aand 30B;

FIG. 32 is an exploded perspective view of assembling four floor panelsusing a beam for the basket of FIG. 27;

FIG. 33 is a detailed view of the intersection of the four floor panelsof FIG. 32;

FIG. 34 is a cross-section view of an intersection between two adjacentfloor panels using a beam for the basket of FIG. 27;

FIG. 35 is an illustration of a front lower corner of the basket of FIG.27;

FIG. 36 is an illustration of the side walls of the basket of FIG. 27;

FIGS. 37A, 37B, 37C, 37D, 37E and 37F are various illustrations of afirst side panel suitable for forming a side of the basket of FIG. 27;

FIGS. 38A, 38B, 38C, 38D, 38E and 38F illustrate an embodiment of asecond side panel configured to mate with the first side panel;

FIG. 39 illustrates the stacking of two side panels according to anillustrative embodiment of the invention;

FIG. 40 is an illustration of the inside of two stacked side panels;

FIG. 41 is an enlarged illustration of region A of FIG. 40;

FIG. 42 is an illustration of the outside of the stacked side panels ofFIG. 40;

FIG. 43 is an enlarged illustration of region B of FIG. 42;

FIG. 44 illustrates a stack of modular baskets according to anembodiment of the invention; and

FIG. 45 illustrates a frame for a poultry colony employing modularbaskets according to an embodiment of the invention.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and will herein be described in detail. Itshould be understood, however, that the drawings and detaileddescription presented herein are not intended to limit the invention tothe particular embodiment disclosed, but on the contrary, the intentionis to cover all modifications, equivalents, and alternatives fallingwithin the spirit and scope of the present invention as defined by theappended claims.

DETAILED DESCRIPTION OF INVENTION

According to the embodiment(s) of the present invention, various viewsare illustrated in FIGS. 1-45 and like reference numerals are being usedconsistently throughout to refer to like and corresponding parts of theinvention for all of the various views and figures of the drawing. Also,please note that the first digit(s) of the reference number for a givenitem or part of the invention should correspond to the Fig. number inwhich the item or part is first identified.

One embodiment of the technology is a single colony basket designadapted to be used throughout poultry processing from the hatchery,through growing and to production. The colony basket includes componentsdesigned for the growing process and components designed for transport.The colony basket is adapted for an automated loading system including astackable tray design, a transport system, and unloading and storingsystem.

The details of the invention and various embodiments can be betterunderstood by referring to the figures of the drawing.

Referring to FIG. 1, a colony basket integrated with a watering andfeeding system is shown. The colony basket growing assembly 100 is shownwith a colony basket 102 having vented vertically upright side walls 104and 106 extending between a top rim flange and a bottom rim flange. Thevertically upright side walls include vented areas 108. The top rimflange includes a plurality of stand-offs as represented by items 110and 111. The stand-offs can provide spacing between colony baskets whenthey are stacked one on top of the other. The bottom rim flange caninclude complimentary recessed receptacles to receive the stand-offstherein in order to interlock the stacked colony baskets and in order toprevent or resist lateral and longitudinal movement. The top rim flangeand the adjacent side wall can have vertical slots 116 and 118 forreceiving the water channel and water trough assembly 120 and 122. Thecolony basket 102 can also be integrated with a feed channel 124 andfeed trough 126. The feed assembly and the watering assembly can be moregenerally referred to as sustenance assemblies that can be elevatedabove the basket for basket removal and installation and ultimatelylowered into the basket. The parametrical top rim flange defines anupward facing opening through which birds can be inserted into thebasket. The downward facing opening is closed by a floor 112 providingsupport and a trap for debris. The floor 112 can have placed thereonelongated elevator strips 114 over which a flexible mesh flooring (NotShown) can be supported and installed. The flexible mesh flooring, notshown, can have small openings through which debris can fall downwardthrough the mesh flooring and be trapped by the floor 112. Theflexibility of the mesh flooring prevents injury to birds standingthereon. The colony basket growing assembly 100 is shown in itsconfiguration when it is integrated within a colony system whereby thebirds are housed within the colony basket and provided nourishment forthe growing process. For another embodiment, the floor 112 can be a meshfloor and the strips 114 can support the mesh floor. A furthermodification to this embodiment can include an under panel or cover thatremovably attaches immediately underneath the mesh floor 112.

Referring to FIG. 2, a colony basket stack is shown. In FIGS. 2A-2Cvarious views of a colony basket stack 200 is shown. The colony basketsare shown stacked one on top of the other. The colony basket stack 200can be transported in this configuration and as seen in the variousviews, the colony baskets are vertically spaced one with respect to theother by the stand-offs 111 and 110. The bottom facing rim of the basketabove can be configured with a mating receptacle recess for receivingthe stand-off of the basket immediately below.

Referring to FIG. 3, a colony basket rack is shown. A rack assembly 300is shown and configured for a colony system. The rack transfer andconveyor assembly 302 is shown which is utilized to support the colonybasket as well as transfer the colony basket into and out of the colonyracks of the colony system. The colony system configuration is shownwith a feed assembly 304 and a watering assembly 306. The slot 116 shownwhere the water assembly 306 can be lowered therein. The feed assembly304 and the water assembly 306 is shown in a lowered position but can beelevated above the colony basket using a wench system adapted to raiseand lower the assemblies so that the basket can be inserted and removedfrom the colony basket rack without being obstructed by the assemblies.Other drawer designs are not adapted such that watering and feedingassemblies can be raised above or lowered into the container.

Referring to FIGS. 4A through 4E, a colony basket rack is shown, a sideplan view of a colony basket is shown, a side plan view of a colonybasket is shown, a colony basket rack support is shown and a colonybasket rack conveyor assembly is shown. FIGS. 4A-4E show the variouscomponents of the rack assembly 300 within the colony systemconfiguration. The colony baskets are longitudinally installed withinthe rack assembly 300. The longitudinal installation aligns the verticalslots of the colony baskets to be aligned with the water trough system.The components of the transfer system including the support transferrack 400 and the rack transfer conveyor assembly 302 is also shown.

Referring to FIGS. 5A-5B, a colony basket rack support is shown and acolony basket rack conveyor assembly is shown. FIGS. 5A and 5B showfurther detail of the support transfer rack 400 and the rack transferconveyor assembly 302. The rack transfer conveyor assembly 302 includesa conveyor belt 500 and a conveyor roll assembly 502. The rack transferconveyor assembly 302 also includes a hydraulic cylinder extension arm504 that can be utilized to engage the baskets with engagement members506 and extend to transfer a colony basket stack from one rack toanother and/or from one rack to a transport system. The basket cylinderarm and basket retention bar 504 can be actuated to longitudinallyextend and retract during retrieval and insertion of a basket. Thebasket retention bar 504 can include basket engagement members memberthat engages the basket by applying lateral pressure against the side ofthe basket and/or engages a complimentary receptor configured to receivethe engagement member. The retention bar and engagement member can berotated about pivot 508 in order to rotate upward to engage a basket orto rotate outward and downward away from the basket. The supporttransfer rack 400 can support a basket and the support transfer rack canbe integral with a rack allowing the transfer rack 400 to elevate orlower the basket with the rack when it is supporting a basket.

Referring to FIG. 6 a flow diagram of the colony basket methodology isshown. FIG. 6 shows a flow diagram of a circular process utilizing asystem of colony baskets throughout the entirety of the process. A givencolony basket will retain the same colony (grouping) of birds throughoutthe process. Initially a colony basket is filled with DOC at a hatcheryas reflected by step 600. Groupings of colony baskets each containingtheir own individual grouping of birds are then transferred to a growinghouse (colony farm) 602 where the baskets are loaded into a colonysystem as reflected by 604. The birds are retained in the same colonybasket in which they were originally installed throughout the growingprocess and the growing process proceeds as reflected by 606. The colonybaskets are integrated with the watering and feeding systems within thecolony system of the growing house. Once the growing process has beencompleted, the birds are retained in their original colony basket andthe baskets are removed from the colony system and transferred to thetrailer of a transport as reflected by step 608. The transport carriesthe grouping of baskets to a processing plant where the colony basketsare stacked and stored for future processing as reflected by steps 610and 612. Again, each of the grouping of birds are retained in theiroriginal colony basket throughout the process. The baskets are unloadedas reflected by step 614 and transferred to the kill line as reflectedby step 616 or 617 which may be a controlled atmosphere stunning system(CAS) path and there can be separate paths that can be chosen. The birdscan be removed from the original baskets in which they were placed andinstalled on shackles for further processing. The baskets can then besent through a cleaning process as reflected by step 618. The cleanedbaskets can then be transported to a hatchery 620 and a new batch of DOCcan be installed into the baskets and the process can repeat itself.

Referring to FIG. 7, an illustration of the hatchery conveyor is shown.FIG. 7 is an illustration of a hatchery system where groupings of DOC700 can be placed on a conveyor system 702 and transferred into colonybaskets by a transfer system 704 and the baskets filled with DOC canthen be stacked and transferred to a growing house containing a colonysystem. The transfer system 704 installs the DOC in a basket andseparates the DOC from the shells that remain after the bird hatches.

Referring to FIG. 8, an illustration of a colony system is shown. FIG. 8is an illustration of a colony system where rows of rack assemblies 800are aligned side-by-side in which colony systems are installed asreflected by Items 800 and 802 respectively. A rack assembly 300 can beutilized for transferring the colony baskets from the rack to the colonysystem. The colony baskets can be longitudinally installed within thecolony system for the growing process. The colony basket stacks 200 canbe installed on wheeled platforms for transporting the colony basketsstacks as reflected in the illustration.

Referring to FIG. 9, an illustration of loading colony baskets from arack to a colony system is shown. FIG. 9 is a further illustration oftransferring a colony basket stack 900 on a wheeled platform 902 to acolony rack 302 for insertion of the colony baskets into the colonysystem as reflected by Items 800 and 802.

Referring to FIG. 10, an illustration of the colony system operation isshown. FIG. 10 is an illustration of the growing process in operationwhereby workers 1002 utilizing platforms 1004 can tend to the growingprocess by maintaining the watering and feeding systems. The water andfeed assemblies are shown in an elevated position above the basket. Whenthe assemblies are elevated, the baskets can be readily inserted andremoved.

Referring to FIG. 11, an illustration a transport loading system isshown. FIG. 11 is an illustration of transferring colony baskets 102from a colony system into a rack assembly 300 for transfer into thetransport 1104 having a flatbed 1106. The colony baskets 102 can betransferred by a transfer conveyor 1102 into a rack assembly 300. Therack assembly 300 can then be utilized to load the transport 1104 byplacing the colony basket stacks on the flatbed of the transport.

Referring to FIG. 12A-12C, an illustration of loading a transport isshown. FIGS. 12A-12C is a further illustration of transferring colonybaskets from the colony system onto a rack assembly for placement on aflatbed of a transport.

Referring to FIG. 13-19, an illustration of transferring colony basketstacks from a colony system to a trailer is shown. FIGS. 13-19 providean illustration of a step-by-step process for transferring colonybaskets from the colony system onto the flatbed of a transport. Asillustrated, the basket supports 400 are rotated to receive the firstcolony basket from level 4. The basket is loaded onto the basket supportand a netting material can be installed or draped over the top of thecolony basket 102 to retain the birds therein. FIG. 14 illustratesloading a second basket from level 4 and again applying a netting orother covering material over the top of the basket. FIG. 15 illustratesloading a third basket from level 3 and again applying the nettingmaterial and draping over the top of the basket. This process isrepeated for each of the levels of the colony system as two baskets areloaded from each level and then stacked with the previously loadedbaskets.

FIG. 16 reflects loading the eighth and final basket from level 1 ontothe rack transfer conveyor assembly for subsequent stacking of thecolony baskets. When a complete stack has been loaded, the basketsupports can be rotated outward such that the rack transfer conveyorassembly can begin transferring stacks onto the transport. FIG. 17illustrates the completed stack and ready for rotating the basketsupports outward to ready the loading of the basket stacks onto thetransport. FIG. 18 illustrates the rack transfer conveyor assemblyconveying the basket stacks onto the flatbed of the transport. FIG. 19illustrates the completion of the stack loading utilizing the hydrauliccylinder extension arm 1902 for placing and loading the stack onto theflatbed of the transport.

Referring to FIGS. 20-22, an illustration of retrieving colony basketstacks from a trailer is shown, which is essentially the reverse of theprocess for loading a trailer. FIG. 20 is an illustration ofsubsequently retrieving the basket stacks from the trailer using thehydraulic cylinder arm to engage and pull the stack onto the rackassembly. The hydraulic cylinder arm pulls the stack onto the rack andonto the conveyor for subsequently engaging the support transfer racksfor installing and longitudinally inserting the basket into the colonysystem. FIG. 21 illustrates the beginning of the process fortransferring the basket stacks into the colony system. The transfersupport racks can be rotated to engage the colony baskets to begin theprocess of transferring the baskets into the colony system. A reversalof the previous process can be performed by installing two colonybaskets per level, beginning with level 1 and moving upward to level 2,3 and 4. FIG. 22 is an illustration of this process.

Referring to FIGS. 23-24, illustrations of transferring colony basketsto a kill line are shown. FIG. 23 is an illustration of transferring thecolony baskets from the transport to the rack assembly 300 and thentransferring the colony baskets onto the colony basket entry conveyor2302 to convey the colony baskets to the rendering station 2304. Oncethe birds have been unloaded from each colony basket, the empty colonybasket can then be transferred to the colony basket exit conveyor 2306.The colony baskets can then proceed through and along the colony basketwash conveyor 2308 which carries the colony baskets through the colonybasket washer 2312. The colony baskets once they are washed can then bereconfigured in a colony basket stack 2310 where the process can bestarted again.

FIG. 24 is an illustration of a colony basket entry station 2402 whichis another embodiment for transferring the colony basket stacks from thetransport to the rendering station.

Referring to FIGS. 25-26, an illustration of colony baskets travelingthrough the kill line and the cleaning station is shown. FIG. 25 is afurther illustration of the rendering or kill line whereby workersremove the birds from the colony baskets and hang the birds on thehanging conveyor shackles 2502.

The process can begin at the hatchery where a grouping of birds (forexample DOC) are gathered and placed into a colony basket. A pluralityof baskets can be stacked on over top of another for transport. Anetting material can be shrouded over each colony basket to assist incontaining the birds. The grouping of birds and their respective colonybasket in which they are placed can remain in the same colony basketthroughout the process until they are removed as broilers at the killstation. This reduces the handling of the birds to avoid injury andhelps to prevent the spread of bacteria or disease between birdgroupings. The grouping of DOC can be transported to a growing house inthe same colony basket in which they were originally placed at thehatchery, where the poultry are grown for future processing. At thegrowing location there can be a series of growing colony racks forhousing the colony baskets with the original grouping of birds placedtherein at the hatchery. At the growing facility, the colony baskets canbe integrated with water and feed channels and watering and feedtroughs. The colony baskets can have a specific configuration tointegrate with the watering and feeding systems as outlined herein inorder to assist poultry going through the growth process and assist theoperators at the growing facility for attending to the birds. When thepoultry have completed the growth process, now in the broiler stage,they can be transported to a location for processing as a final foodproduct. A transport can arrive at the growing location to receive thepoultry that have completed the growth process. The transport system canbe a truck and trailer combination. The trailer can be a standardflatbed trailer on which colony baskets containing the fully grownpoultry can be loaded. The colony baskets containing the originalgrouping of birds, or some subset thereof, can be transferred from thecolony racks of the colony system to the flatbed of the transport. Anetting material can be shrouded over each basket before it is stackedin order to assist in retaining the bird. The colony baskets can bestacked one atop another. The transport can be loaded with the fullygrown birds and transported along a travel route to an unloading stationat a processing facility. The transfer system for transferring thecolony baskets from the colony racks to the flatbed can be automated asdescribed herein.

The unloading station can include an automated unloading system forautomatically unloading a colony basket stack from the trailer forstorage in an adjacent storage area of the processing facility. Traystacks can be conveyed to a storage location having a climate controlledstorage facility for housing the poultry in the stacked configurationprior to the rendering process. The storage area can be operated on afirst in first out system such that a given colony basket stack does notdwell in the storage area for an extended period of time. The storagearea can also have a system for controlling and tracking the weight ofthe tray stacks which could ultimately provide weight informationregarding the fully grown poultry.

Within the storage facility there can be an automated unstacking systemfor unstacking the colony basket stacks for conveyance through theprocessing facility. There can be a stunning system utilized including agaseous environment for stunning the poultry or it can include anelectric shock stunning system or a combination of the two. If a gaseousenvironment stunning system is utilized, the gaseous environment can bea multi-stage stunning system where the first stage(s) can be a combinedinduction phase and the second stage(s) can be the combined stunningphase. This system can generally be referred to as a controlledatmosphere stunning system or CAS. Once the colony baskets containingthe original grouping of birds/poultry have transitioned through thestunning system, the poultry can be unloaded from the trays at anunloading station. The unloading station can comprise an automatedunloading system which is operable to tilt the colony basketssufficiently to remove the stunned poultry from the colony baskets. Thisis the first point in the process that the birds are removed since theiroriginal placement into the colony basket at the hatchery as DOC. Onceremoved from the colony baskets, the stunned poultry can be conveyed toa shackling station where the poultry can be hung from a shackleconveyor for being conveyed to a plant evisceration facility.

As described the colony baskets can be stackable. Further the colonybasket can have an interwoven wire mesh elevated floor above the colonybasket bottom floor where the mesh openings are sufficiently large fordebris to pass therethrough and also providing a means for the bird tograsp hold in order to stabilize itself and the mesh floor can beflexible in order to avoid injury to the birds. The frame of the colonybaskets include various portions including perimeter top and bottom rimflanges and upright vented side walls. The upward facing surface portionof the upper perimeter top rim flange can be designed to becomplimentary with respect to the downward facing portion of the bottomperimeter rim flange. This complimentary configuration can be designedsuch that the trays interlock when they are stacked thereby resistinglongitudinal and latitudinal movement of the trays with respect to eachother.

The stackable tray can be constructed having a top rim flange and abottom rim flange, which defines the longitudinal and latitudinaldimensions of the tray. The top and bottom rim flanges can have L-shapedcross sections. The inner perimeter of the top rim flange can define anupper opening or upward facing opening through which birds can be easilyinserted. The bottom rim flange defines the perimeter of the lower ordownward facing opening closed off by the solid floor. The solid floorcan have elevators for elevating the mesh floor proximately above thesolid floor. The mesh flooring is designed with vented openings wherethe openings are sufficiently large to allow debris to pass therethrough. The flexible mesh floor design provides for a surface that canbe grasped by the talons of a bird without injury. Upright side wallscan be attached around the perimeter of the tray and attached to supportmembers. The inner perimeters of the top rim flange and the bottom rimflange, which define the upper and lower openings respectively, can havesubstantially the same geometry.

The top rim flange can include stabilization standoffs which can extendvertically. The top rim flange can have on an upper surface a verticalstandoff. The flange and the complementing recessed receptacle on theunderside of the colony basket when engaged, one with respect to theother in a stackable fashion, they can resist longitudinal andlatitudinal shifting of trays, one with respect to the other. Also, thestabilization standoffs can be placed along the latitudinal andlongitudinal sides of the top rim flange. The spacing between thelongitudinal, the latitudinal, and the corner upright support ribsdefine the vented openings of the tray. The spacing between the supportmembers and the height of the support members can be optimized dependingon the type of bird being contained within the stackable trays.

For stacked colony baskets the uppermost colony basket can have a topcover or a netting installed of the uppermost colony basket. The topcover can have a mesh screen for covering the opening of the uppermosttray. The perimeter of the mesh screen can be defined by the top coverflange. The top cover flange can have recessed receptacles forinterfacing with the raised standoffs of the uppermost tray.

The colony basket stacks can be transitioned to the transport and loadedon the flatbed by way of a transfer rack or loading dock or other meansfor loading the colony basket stacks. Vertically protruding standoffscan be provided on the flatbed for and dimensioned to be received by therecessed receptacles of the lower most colony basket in a stack. Thetransport can have a shroud covering for better controlling theenvironmental exposure of the poultry. The shroud covering can besupported by transport side rails. One or both of the side panels of theshroud covering can be a retractable curtain for exposing the flatbedfrom either side. The shroud covering can also have a rear transportcover opening and or a side transport cover opening through which colonybaskets can be loaded.

The stacked colony baskets can be loaded through the transport coveropening by sliding them along tray tracks which extend along theflatbed. The trailer can be a standard trailer; however, the trailer canhave side railings for supporting shroud covering. The top surface ofthe flatbed can have raised standoffs that conform to the recessedreceptacles on the underside of the tray to restrict lateral sliding ormovement of the bottom most tray.

The technology described above includes an additional embodiment. In theadditional embodiment, the colony baskets described herein above arereplaced with modular baskets. The modular baskets may be utilized andintegrated interchangeably with the invention described above.

FIGS. 27, 28 and 29 illustrate an implementation of a modular basket2710 suitable for raising poultry or other animals and-or fortransporting a product. The illustrative basket 2710 is a modularplastic basket formed of a plurality of interlocking plastic panels. Thepanels can be formed by injection molding, though other suitablematerials and processes may be used to form the panels. In oneembodiment, the panels are made of polypropylene and are connected usingstainless steel beams. The modular basket 2710 is interchangeable withcolony baskets 102 in the invention described herein above and can befully integrated with other colony baskets in the overall systemincluding integrating with the watering and feeding systems.

Each basket 2710 comprises a floor formed by an array of interconnectedmolded plastic floor panels 2720. The floor comprises a plurality ofcorner panels, edge panels and middle panels. Each floor panel can beformed as a flexible mesh panel for allowing animal waste and otherdebris to drop through while providing a comfortable surface forpoultry. In the illustrative embodiment, each floor panels 2720 areidentical and formed from the same mold, though the invention is not solimited.

Interconnected side panels 2750 are connected to the floor panels 2720to form side walls for the basket 2710. As described below, the sidepanels receive beams that connect the floor panels to each other toconnect the side panels to the floor. The side panels have pliable meshof expanding size. As also described below, the basket 2710 comprisesside panels having at least two different, but similar configurations.

The basket 2710 has an open top, though the invention is not so limited,and when the sides are assembled, recesses 2751 can be formed to receivewatering and feeding systems.

The basket 2710 is stackable with one or more other baskets to form avertical, space-saving stack of apartments. Multiple stacks may bearranged within a frame, or arranged side-by-side to form a colony.

The basket as illustrated comprises twenty-five floor panels 2720 andfourteen side panels 2750, though one skilled in the art will recognizethat any suitable number and arrangement of panels may be used to form abasket of any suitable size, shape and configuration.

In one embodiment, each floor panel can be between about approximatelyfifteen and about approximately twenty inches, and one implementationcan be between about eighteen and about nineteen inches, by betweenabout approximately twelve and about approximately fifteen inches, andin one implementation can be between about approximately thirteen andabout approximately fourteen inches. The side panels have a heightbetween about approximately eight and about approximately twelve inches,and one implementation can be about ten inches and a length betweenabout approximately twenty inches and about approximately twenty fiveinches.

The basket 2710 as illustrated and described may hold about ten lbs persquare foot. The number of birds each basket holds depends on theintended slaughter weight of the bird. In one implementation, the basket2710 may hold about 90 six pound birds, about 140 four pound birds orabout 209 2.2 pound birds.

FIGS. 30A, 30B, 30C, and 30D illustrate a single floor panel 2720suitable for forming a floor, or a portion of a floor, of a modularbasket 2710. FIG. 31 is a detailed view of a corner of the floor panel2720. Each floor panel comprises a flexible mesh floor 3022 extendingbetween edges 3024, 3025, 3026 and 3027. A front support beam 3028extends below edge 3024 and a rear support beam 3029 extends below edge3025. The strands forming the mesh 3022 preferably have rounded tops tofacilitate run off. In one implementation, the strands have a circularcross-section that is between about 0.100″ and about 0.140′ in diameter.The illustrative strands form square openings 3123 that are betweenabout 0.375″ and about 0.615″ across, though the invention is notlimited to the illustrative size and shape. The flexible mesh floorpreferably has a certain flexibility to promote comfort and cleanliness.In one embodiment, the flexible mesh floor deflects about 0.5 inches atsize pounds of weight in the center. The flexible floor may be morecomfortable for the animals. In addition, the flexing may contribute todried manure cracking off without requiring additional cleaning.

The edges slope downwards to create a bowl channeling debris through themesh openings 3023. As shown in FIGS. 30A, 30B, and 31, the corners ofeach floor panel 2720 form downward sloping ramps 3041 for channelingdebris through the mesh openings. The illustrative ramps 3041 aretriangular in shape and widen from the top to the bottom.

The center of the floor panel 2720 may be solid for injection moldingpurposes.

The floor panels 2720 include hinge elements 3032, 3033, 3034, 3035extending below the mesh floor 3022 from each end of edges 3026 and3027. A first pair of hinge elements 3032, 3033 extends down from edge3026, and a second pair of hinge elements 3034, 3035 extends down fromedge 3027. The second pair of hinge elements is offset from the firstpair. As shown, hinge 3033 is positioned at a corner of the generallyrectangular floor panel, whereas hinge 3032 is offset from the corner ofthe floor panel thereby allowing hinge 3034 of an interfacing abuttingfloor panel to be position adjacent hinge 3032 and aligned such thatbeam 3280 may be inserted through the hinge openings. Similarly, on theopposing side of the floor panel, hinge 3034 is positioned at the cornerof the floor panel and hinge 3035 is positioned such that it is offsetfrom the corner of the floor panel. Therefore, hinges 3033 and 3034 atdiagonally opposing corners of the floor panel are positioned at thecorner and hinges 3032 and 3035 are offset from the corner. FIGS. 32 and33 illustrate the connection of a plurality of the floor panels 2720using a beam 3280. As shown in FIGS. 32 and 33, the hinges 3032, 3033,3034 and 3035 receive a beam 3280 for linking the floor panels together.The illustrative hinge elements include sloped upper surfaces 3036, flatsides and flat bottoms, though the invention is not so limited. Eachhinge element includes a hinge opening 3039 for receiving the beam 3280.The illustrative hinge openings 3039 are bone shaped to ease beaminsertion and facilitate manufacturability. The illustrative beam 3280has a rectangular cross-section, but the invention is not so limited.

As shown in FIGS. 32 and 33, a beam 3280 may be used to join two columnsof floor panels to form a floor of a basket, such as the basket 2710 ofFIG. 27. The illustrative basket 2710 of FIG. 27 has five columns offloor panels 2720 in five rows, connected using six beams 3280, thoughthe basket may comprise any suitable number of floor panels in anysuitable arrangement. In addition, the floor may comprise multiple beams3280 per column. FIGS. 32 and 33 show four floor panels 2720 a, 2720 b,2720 c, 2720 d joined together by aligning the hinge elements 3034 and3035 of the left floor panels 2720 a, 2720 b with the hinge elements3032, 3033 of the right floor panels 2720 c, 2720 d and inserting a beam3280 through the aligned hinge elements.

As clearly illustrated in FIG. 30C, the front hinge elements 3032 and3034 of each floor panel are offset from each other, so that the hingeelement 3032 of a right floor panel 2720 c or 2720 d is adjacent to andbehind the hinge element 3034 of a left floor panel 2720 a or 2720 bwhen the floor panels are joined. The hinge element 3032 is spaced fromthe front edge 3024 of the floor panel by a distance that is equal to orgreater than the width of the hinge element 3034 along the length ofedge 3026, so that the corresponding hinge element 3034 fits between thefront of the floor panel and the hinge element 3032. The rear hingeelements 3033, 3035 are also offset from each other to allow alignmentof the hinges when the edges of the floor panels are brought together.The hinge elements of mating floor panels may abut each other or bespaced apart when joined. The floor panels may have more or fewer hingeelements that interlace.

As shown in FIGS. 30A-34, each of the edges 3024, 3025, 3026 and 3027includes lips 3044 that protrude from the edges. The lip 3044 in oneimplementation extend along a portion of an edge and is offset to oneend of the edge. The lip 3044 is offset to one end of 3025, whereas thelip 3044 is offset to an opposing end of edge 3024. Edges 3024, 3025,3026 and 3027 also slope downwards to promote debris channeling throughthe mesh 3022. Edges 3026 and 3027 are complementary, and edges 3024 and3025 are complementary, so that the lips of one edge, such as edge 3027,fit in recesses between lips of a mating edge, such as edge 3026, asshown in FIG. 30. The shaped edges ensure that there is no seam over thebeam 3280 to promote cleanliness. The overlapping edges ensure that theseams between the adjoined floor panels remain covered even as theweight of the animals increases and flexes the floor panels. Inaddition, the edges 3024, 3025, 3026 and 3027 extend inwards past thebeam 3280 by a selected amount to promote the channeling of debristhrough the mesh 3022 and prevent soiling of the beam 3280. Thus, theoutside edges of the floor 3022 are solid to protect the beam 3280. Forexample, in the embodiment shown in FIG. 34 the distance D between thefront of the beam 8320 and the interface between the edge 3027 and mesh3022 is at least 0.25″ and preferably at least 0.5″. Lip 3044 extendsover edge 3026 as illustrated in FIG. 34 so that the seam is sealed.

The side panels 2750 connect to the floor using the beams 3280. FIG. 35is a detailed view of area 3 of FIG. 29, showing the connection betweena beam 3280 and a side panel 2750 forming a side wall of the basket2710. The beam 3280 that passes through and joins adjacent columns offloor panels passes into an opening 3552 in the side panel. The opening3552 includes recesses to allow twisting of the beam end to lock thebeam into place. In the illustrative embodiment, each beam 3280 linkingtwo columns of floor panels passes into an opening in a side panel, butnot all side panels receive beams. The edge beams 3280 extend throughthe hinges of the floor panels along each opposing end forming the shortside of the basket floor and the edge beam also extends through thehooks 3769 of each side panel extending along the short side of thebasket and these edge beams 3280 extend into the opening 3552 of a sidepanel 2750 b extending along a long side of a basket and adjacent acorner.

The side panels 2750 are connected together to form the side walls ofthe basket 2710. In the illustrative embodiment, each side panelincludes links along the first side and second side edges for connectingthe side panel to an adjacent side panel. The links are configured suchthat the side panels may be connected at either 90° or 180°, as shown inFIG. 36 to form a corner of a side wall. Items 2750 a and 2750 b can beconfigured at a 90 degree angle to form a corner portion of the sidewall.

The illustrative basket comprises four different configurations of sidepanels, each with similar features, as described below.

FIGS. 37A-37F are various views of a first side panel 2750 a suitablefor forming a side of a modular basket. The illustrative side panels2750 a are used adjacent to diagonally opposite corners on the shortside of the basket 2710 of FIG. 27. Each side panel comprises a meshwall formed between upper, lower and side edges. Each side panel 2750includes female links 3762 on a first side and male links 3772 on anopposite side. The female links each comprise a protrusion 3763extending from the side edge. The protrusion forming the female linkincludes two intersecting recesses 3764, 3765. The recesses 3764 and3765 are perpendicular and have a square-shaped cross-section. The malelinks 3772 comprise protrusions 3773 aligned with spaces 3766 betweenthe female protrusions. Rods 3775 extend between the protrusions. Theillustrative rods 3775 have a square cross-section, with a thicker upperportion and a thinner lower portion. The female links 3762 receive themale links 3772 at either a 90° or 180° to connect two side panelstogether. As shown in FIG. 36, a u-shaped pin 3679 may be inserted intoa space between the female protrusions 3763 and male protrusions 3773 tohold the links in place.

The side panels 2750 a further include hooks 3769 extending from thebottom edge for receiving edge beams 3280 that connect floor panelstogether.

The side panels 2750 a further include a cavity, illustrated as recess3781, formed in the top edge for allowing the passage of feeding tubesor pipes. As illustrated, these side panels 2750 a can be positioned toextend along the short side wall of the basket adjacent the corner ofthe basket.

An inside ledge 3791 extends between the links 3762, 3772 above the beamopenings 3552. The ledge 3791 slopes downwards and overlaps the floorpanels 2720 when the basket is assembled to promote cleanliness. Evenwhen the floor panels bow under the weight of animals in the basket, theoverlap between the inside ledges 3791 and floor panel edges preventseparation between the components.

Above the ledge 3791, the space between the edges of the panels forms anexpanding mesh 3793. The openings 3795 in the mesh 3793 grow larger thehigher they are to accommodate growing poultry. In one implementation,the openings are between about approximately one and about approximatelythree inches wide, where in one implementation the openings are aboutapproximately 2.2 inches and between about one and about approximatelytwo inches tall, preferably about approximately 1.5 inches tall.

The side panel 2750 a further includes openings 3797 below the ledge3791 to promote airflow. The side panels used in the opposite cornersfrom the side panels 2750 a are substantially similar, except for thelength of the inside ledge 3791.

FIGS. 38A-38F illustrate an embodiment of a second side panel 2750 bconfigured to mate with the first side panel 2750 a. A second side panel2750 b is disposed between two first side panels 2750 a on the shortside of the basket 2710 of FIG. 27, and a series (four, in theillustrative embodiment) of second side panels are connected at 180°angles along the long side of the basket 2710. The second side panel2750 b includes the same female and male links, mesh, ledge, hooks andopenings and further includes a stacking tip 3851 extending upwards fromthe top edge. The bottom edge includes a recess 3861 for receiving thestacking tip of a side panel in a basket below. For the long side of thebasket, the second side panel 2750 b has a minimal inside ledge 3791.

FIGS. 39-43 further illustrate the means by which side panels 2750 b ofbaskets 2710 stacked on top of one another engage one another. Asillustrated, stacking tip 3851 includes a pyramid-shaped protrusion 3852having a flat front face 4153 and two straight protrusions 3854, 3855opposing the pyramid-shaped protrusion for gripping the bottom edge ofan overhead panel. When stacked, the stacking tip allows for a space4070 to be formed between the overhead and below baskets.

FIG. 44 illustrates a stack 4400 of nine modular baskets 2710. Multiplebaskets may be stacked together for transportation as described in theprevious embodiment. The baskets are self-stacking and stabilized on topof each other.

FIG. 45 illustrates a frame 4500 for a chicken colony employing modularbaskets. The frame includes multiple levels, each level housing a row ormore of modular baskets. A conveyor belt may be used to convey themodular baskets 2710 on and off of the frame as described in theprevious embodiment.

The illustrative modular plastic basket provides a comfortable,sanitary, accessible environment with optimal air flow and ventilationfor raising chickens or other products. The modular plastic baskets areeasily assembled and stackable to save space.

Poultry can be raised in the basket from the beginning to the end oflife. The basket may be easily removed from a poultry house and truckedto a process facility, where it is unloaded, cleaned, then sent back toa hatchery or poultry house.

The various poultry handling examples shown above illustrate a novelsystem and method for handling poultry. A user of the present inventionmay choose any of the above chicken handling embodiments, or anequivalent thereof, depending upon the desired application. In thisregard, it is recognized that various forms of the subject chickenhandling could be utilized without departing from the spirit and scopeof the present invention.

As is evident from the foregoing description, certain aspects of thepresent invention are not limited by the particular details of theexamples illustrated herein, and it is therefore contemplated that othermodifications and applications, or equivalents thereof, will occur tothose skilled in the art. It is accordingly intended that the claimsshall cover all such modifications and applications that do not departfrom the spirit and scope of the present invention.

Other aspects, objects and advantages of the present invention can beobtained from a study of the drawings, the disclosure and the appendedclaims.

What is claimed is:
 1. A floor for a modular basket, the floorcomprising: a first floor module comprising a mesh floor extendingbetween a plurality of edges, a first set of hinge elements includinghinge openings extending below the mesh floor from a first edge and asecond set of hinge elements including hinge openings extending belowthe mesh floor from a second edge, the second edge located opposite thefirst edge; a second floor module adjacent the first floor module, thesecond floor module comprising a mesh floor extending between aplurality of edges, a first set of hinge elements including hingeopenings extending below the mesh floor from a first edge and a secondset of hinge elements including hinge openings extending below the meshfloor from a second edge, wherein the second edge is adjacent to thefirst edge of the first floor module; and a first beam extending througha first set of hinge openings of the first floor module and a second setof hinge openings of the second floor module, thus connecting the firstfloor module and second floor module.
 2. The floor of claim 1, furthercomprising a third floor module connected to the first floor moduleusing the first beam.
 3. The floor of claim 2, further comprising afourth floor module connected to the second floor module using the firstbeam.
 4. The floor of claim 1, wherein the first edge of the first floormodule includes a lip that mates with a recess on the second edge of thesecond floor module.
 5. The floor of claim 1, wherein one of the firstset of hinge elements and one of the second set of hinge elements arepositioned diagonally opposite at opposing corners of the mesh floor. 6.The floor of claim 1, wherein one of the first set of hinge elements andone of the second set of hinge elements are positioned diagonallyopposite and proximate opposing corners of the mesh floor and the one ofthe first set of hinge elements and the one of the second set of hingeelements are offset with respect to one of the opposing corners.
 7. Thefloor of claim 6, where the opposing corners of the mesh floor areformed having downward sloping ramps for channeling debris through themesh openings where each downward sloping ramp is triangular in shapeand widen from the top to the bottom.
 8. The floor of claim 1, where themesh floor is formed of a plurality of crisscrossing strands forming themesh having at least one rounded top to facilitate run off.
 9. The floorof claim 8, where the strands have a circular cross-section and thecrisscrossing strands form square openings.
 10. The floor of claim 9,where the crisscrossing strands form a flexible mesh floor, whichdeflects about 0.5 inches at size pounds of weight in the center. 11.The floor of claim 1, where the hinge elements are formed with slopedupper surfaces adjacent the mesh floor and said hinge elements areformed with flat sides and flat bottoms distal with respect to thesloped upper surface.
 12. The floor of claim 11, where the hingeopenings are bone shaped to ease beam insertion and facilitatemanufacturability.